Roofing and siding material



July 9, 1940. s, A, @CHS 2,206,915

ROOFING AND SIDINCr MATERIAL Filed NOV. 2l, 1956 ATTORNEY Patented July9, 1940 UNITED STATES 2,206,915 ROOFING AND SIDING MATERIAL Sidney A.

Ochs, New York, N. Y.,

assigner to Bakelite Building Products Co., Inc., New York, N. Y., acorporation of Delaware Application November 21, 193s, serial No.112,005 6 Claims. (Cl. 91-68) .This invention relates to individualshingles, strips, and roll roofing for` use in covering roofs and sidesof buildings, andy to improvements therein providing substantialprotection of the weather surface particularly against discoloration andmarring during handling in manufacture, packaging, rolling, in storageand during application to a building surface.

More particularly, the invention concerns l0 composition materialgenerally comprising a bitumen, for example, asphalt, saturated and.coated fibrous base which is usually provided with an ornamental weatherfacing, for instance, a layer of individual granular mineral particles,and/or especially a continuous layer of cement, for example, thatdescribed in Harshberger U. S. Patent No. 1,913,667, granted June 13,1933.

In the production of granule faced composition material, it has beencommon practice to apply the granules as a final operation while thebase bituminous coating is hot and sticky, and subsequently to eitherform suitable lengths into rolls or cut the fabricated web intoindividual shingle units or strips and stack these into bundles ofsuitable number for shipment and/or storage. With either product aplurality of contacting layers of thc surfaced material are obtained,the ornamental granule facing of one touches or substantially contactsthe bitumen face of the next, and so on. Under these conditions and injarring of the bundles in handling, certain layers Aundergo considerablepressure and adhesion of bitumen to the granules may take place, so thatwhen the layers are separated a bituminous blemish may remain uponthegranules. This is especially true rwhen the bitumen is somewhat softor tacky at the time of forming the contacting layers. Also, in certaininstances staining and discoloration of the granules occur by theabsorption of the bituminous oils, and both this and the foregoingundesirable results are believed to become more marked by extendedperiods of storage.

Sometimes fine mica or talc have been dusted upon the bitumen treatedbase of the material to resist adhesion between layers, and a skin layerof a higher melting point bitumen than the base saturant has also beensuggested over the back of the base material where intended forshingles,

but these additions have not obviated the aforesaid undesirablefeatures, and adhesion or bleeding of the thermoplastic bitumen past themica and/or talc readily manifests itself in storage under warmconditions.

The blemish, `for instance, of bitumen is even mildew may be a furtherblemish to result.

thermore, the use of an oil or wax over the back o l more marked as aresult of handling, particularly during application to a surface where aconsiderable amount ofabrasion occurs through souffmg between the roughornamental granule surfacing and the back face of pairs of units or lllayers. The surfacing is generally of a hard material having irregularoutlines including sharp proiections and readily 'removes some of theasphalt or the like from the contacting face. Thus, an asphalt blemishreadily results, causing dlsl0 coloration and marring of the ornamentalsurfacing, all of which detracts from the final appearance of anysurface covering, and leads to consumer sales resistance. Moreover,while the described results are readily perceivable with in- 16 dividualgranule surfacings, they are even more manifest where the ornamentalfacing is one of an argillaceous cement, for example, a hydraulic cementor similar binding or coating material. In the latter instance thefacing is generally a ,o continuous one and provides more surface areato contact or scuff the bitumen face. Also, it provides a good roughsurface for holding the blemish producing substance.

However, with either type of surfacing the blemish is' particularlyundesirable where the surfacing comprises -a design of white, buff orother light color effect. Obviously, ,the result is more serious wherethe surfacing is a continuous one than where it consists of interspersedindi- .o vidual granules.

The use of temporary or permanent bitumen resistant coatings over theface Agranules of granule surfaced material to avoid staining in storagedoes not free the rough surface thereof of the susceptibility ofmarking, as by adhesion and abrasion in scuing, with the bitumen back ofan adjacent piece of material. Also, where these coatings are of a watersoluble character,

Fur-

of cement faced material to resist' adhesion of the plastic cement withthe back of an adjacent layer in curing, or the inclusion of a syntheticresin inl the cement composition to form' a surface separating nlm, mayboth be suitable for 45 the intended purpose of preventing adhesion ofthe adjacent faces in setting of the cement, but will not overcomediscoloration, staining and marking of the cement surface by the blemishproducing substances, for instance, bitumen in 5. or on the backs ofadjacent layers. The oils will obviously leave a mark upon the finishedcement face of the material; the same will be true of waxes. Mica, alsowill not prevent the described faults as in the case of the mineralsurfaced 55 material, while the resin faced cement will still be markedby the asphalt or other hydrocarbonbacks of other units in scuiiing.Moreover, certain paper separators may be effective in storage toprevent discoloration, but are a, nuisance in PIOCeSSng of the materialduring manufacture and during application and are expensive. Paperseparators also do not avoid scuiiing of the material in handling,particularly application, and its resultant effects upon the product tobe protected, and create a problem of paper disposal for the applicator.

In accordance with the present invention the foregoing objectionsrelative to composition roofing material having an ornamental surfacingare overcome to a marked vdegree by substantially closing ofi the sourceof the difficulties by means not itself a blemish contributor.Accordingly it is -proposed to treat the face opposite the ornamentalweather-face of such material with an adherent coating composition whichwhen hard ened will provide a tough sealing and abrasive resistinglayer. Such layers will have sufficient thickness and hardness as not tobe readily pierced by the contacting individual granule or cementitiousornamental faces of similar material, during scuffing, in normal.handling, or by pressure contact in storage and shipment. The coatingcomposition when hardened will also be adapted to substantially conformto temperature changes without cracking and will be capable of sealingin the asphalt or the like, of the base to prevent bleeding through ofthis bitumen and staining of the ornamental weather face of an adjacentlayer during manufacture, in storage and in application, Furthermore,the coating compositions produce films resistant to the penetration ofmoisture and other agents and the preferred coating compositions yieldhardened lms that are resistant to the alkalis and acids occurring inthe atmosphere. are substantially unaffected by common solvents andcontinued weathering, and also have a freedom from thermoplastictendencies in exposure.

The invention moreover, contemplates the treatment with similarcompositions of the cut, edges of such roong material, particularlythose to be exposed to the weather, to `complete the seal of such edges,and also contemplates the extension of such treatment to edge portionsor the whole top surface of the base. A further feature contemplates alightweight structure of the foregoing character wherein the base is oflighter Weight than the standard felt heretofore 1n use for shinglematerial, yet because of the treatment given the material it possessesgreater rigidity and resistance to deterioration.

These and other objects of the inventiornrelating to the roofingstructure and methods of fabrication will more fully appear from thefollowing description and the accompanying drawing, which, however, mustbe considered as'merely illustrating and in no way limiting theinvention to the embodiment shown and described.

In the drawing,

Fig. 1 illustrates a section of a granule surfaced composition materialmade in accordance with the invention.

Fig. 2 is a sectional view of a modified embodiment of the invention.

Fig. 3 illustrates a cross-sectional view of a further embodiment of theinvention, wherein the structure includes a continuous ornamentalsurfacing.

Fig. 4 is a perspective view of one method of packaging cut units, and

Fig. 5 is a front view of a bundling method commonly employed in theroofing industry.

Referring to the drawing, the body 2 of the material may be a felted onecomprising a rag and/or asbestos fibre composition commonly employed inthe manufacture of prepared roofing. 'I'his base may, however, be one ofa cellulose fibre and not necessarily felted, for instance, it may be ofthe material commonly known as Solka, which is a purified cellulose, i.e., a cellulose processed to remove all useless impurities and leaveonly purified cellulose. This material when made into a base for roofingis tremendously strong, extremely flexible and highly absorbent towaterproofing material such as asphalt. It is, therefore, particularlyadaptable and preferable for light weight structures because of itsgreater strength and life-providing characteristics, as well asresistance to the effects of moisture. A libre base of this character isgenerally saturated with a bitumen, for instance, a low melting pointasphalt by passing the base web through a vat containing such materialin molten condition. Where the fibrous base is not specially impregnatedwith the asphalt, penetration thereof may be obtained by the applicationof such material to the opposite faces thereof by coating means such asa spray. Subsequently, before or after this bitumen treatment of theinvention has taken place, the side to be exposed may be given anadditional layer of bitumen, for instance, one of a high melting pointasphalt, a portion 5 of which material may, as shown in Figs. 2 and 3,extend over the edges of the fibrous base. While such material is inplastic condition, granular material 6, generally coarse, and of thetypes well-known in the roofing industry, for instance, slate, ceramicgranules, brick, shale, gravel, sand, silica, and quartz may be appliedand partially embedded over the surface and edge forming portions ofthis coating. As illustrated in Fig. 2, a skin layer 1 of bitumen, may'also be applied to the back face of the material.

The aforesaid operations are generally conducted upon a moving base web,and such web may be cut into sections commensurate with the type ofunits or roll roofing to be fabricated. It is to be understood that thefurther treatment to be described may also be carried out upon a web,which may also be moving, or cut units may be treated individually or asa moving series.

At any time during the foregoing operations or following them, the sideof the material which is to form the back of the finished article istreated with a coating composition, which, when dry, will, as previouslystated yield a tough and substantially hard film 8 to form a sealinglayer above the base bituminous saturant or back bituminous adhesiveskin layer, to prevent bleeding through of these substances and willhave sufficient thickness and toughness to resist piercing by thecoritacting ornamental surfaces. The coating should be one that will notitself cause marking of the ornamental facing on the weather face of thematerial, through contact therewith, and preferably, the coatingcomposition will be one that will readily dry and harden prior toformation of the material into packages or rolls. Likewise, it ispreferred that the coating film be non-tacky so as to leave no depositupon the weather face of the material when adjacent layers areseparated.

Coating compositions suitable for this invention may consist of, forinstance, a calcium resinate composition made from a .270 (melting.

point) rosin, calcium hydroxide and'calcium acetate in the proportionsof about 100; 5; and ik, respectively, by weight. Such a composition maybe prepared by heating the rosin to 260 C., adding the calcium acetateand a small portion of calcium hydroxide; then holding at 260 C. andgradually adding the balance of calcium hydroxide. This composition willproduce a hard film. A more flexible abrasive resisting and rapid dryingfilm may be obtained by adding 20-30 parts of China-wood oil. Zinc oxideand zinc acetate may be used in place of the calcium hydroxide andcalcium acetate, respectively, if desired, and in about the same orslightly greater amounts to produce a zinc resinate composition.Suitable llers are incorporated in the composition and these further aidin retarding bleeding. These coatings are preferably used where low costis a factor and where the treatment is specifically desired for theconcealed side of the roofing. Hard resins, for instance, ester gumshaving melting points of about 195 F. formed into solutions withsuitable solvents, preferably those which will not act as solvents forthe base asphalt may be used also, but where treatment of the roofing isextended to Weather exposed portions of the roofing, I employ,preferably, a

o dispersion in a volatile solvent of a phenolic resin and prefer anoil-resin composition polymerized to an advanced condition, for examplea modified phenolic resin modified with extending oils, for instance, ahighly polymerized oil, whereby to obtain rubbery characteristics and afiexible film. An oil-resin composition is further preferred as itdeposits a layer upon Aevaporation ofthe solvent that is substantiallyunaffected by atmospheric conditions and common solvents, hassubstantial weather resistance, resistance to moisture absorption,oxidation, alkalis'and acids, dries very rapidly, does not hold on tothe solvent and bonds particularly well to the material to be treated. Asatisfactory composition may.

be formed by ball milling together 100 parts of an oil-resin compositionof this character, 100 parts filler, for example, lithopone, and 100parts of solvent, for instance, toluol.

Coating materials of the foregoing character are preferably reduced to aspray consistency with mineral spirits, such as Solvesso #2 which is apetroleum thinner, generally hydrogenated, which includes high aromaticsolvents, or toluol. or solvents having similar moderately fastevaporation rates and whose solvency rates are not conducive to bleedingof the bitumen through the protective coatings employed for myinvention, before application. A feature of the invention is to applythe coating composition of the invention prior to the application ofcertain hot bitumen portions in order to accelerate and vsubstantiallycomplete evaporation of solvent without any inhibiting means. Forexample by applying the coating to the saturated base prior to theapplication of the high melting point bitumen adhesive layer l upon theweather side, the initial heat of the saturated base is obtained tostart rapid evaporation of solvent, and subsequently the full heat valueof the additional bitumen applications, for example, the subsequentapplication of the adhesive layer l is obtained and evaporation ofsolvent and hardening of the coating is assured. Where, as in Fig. 1, aprotective coating similar to 8 is to be applied directly to edgeportions and adjacent top surface portions of the saturated base tocreate layers I0 and Il respectively, to complete an edge seal suchtreatment may be applied where desirable. prior'to applying the bitumenor other layer I. The layer Il. may extend over the entire surface as inFig. 3, to prevent blistering/effects by the base. The layers 8, Il) andIl in these gures may be applied simultaneously, or at different times.Also certain of these layers may be applied aftery bitumen layers, butas previously indicated it is preferred that bitumen applications followthese protective layers. For example it is preferred that the layer 8 befirst applied and subsequently the bitumen coating l. Obviously, whereas in Fig. 2, a back skin layer of bitumen is provided to reduceabsorption of the protective coating composition, such will obviously beapplied firstand the layer B subsequent thereto.

It will be noted that the protective layer I in Figure `2 extends overan edge portion, normally the weather edge of the material, having underlayers of bitumen and coarse granules and greatly assists in protectingthe asphalt coating at this edge, as well as improving the anchorage ofthe ,granular particles. In certain instances a layer of granularlmaterial I2 may be applied to the edgeportions over the layer I0 toimpart further protection thereto and to further cover the base at this'vulnerable point. Applications of this character are shown in Figs. 2and 3, but may also be included in that of Fig. 1. It is preferred thatthese granules be much finer (about 50-100 mesh) than the granules 8,(generally about a #8 mesh) used on the face of the material in order toobtain more complete coverage. A feature of the inventionresides in thedeferring application of the edgegranules where applied over the layerI0 until such time'as the coating 4 has been applied to the base andbefore these coatings have set or hardened. Following application of thegranular materials the exposed surface and edge portions may, wheredesired',be treated with a further surfacingof, for instance, hydrauliccement I4. A product thus coated is illustrated in Fig. 3.

It is to i@ observed that the treated edge in Fig. 2 is chamfered andsuch will, where the product has substantial thickness, form an exposedand readily observed band of contrasting effect with `the normal weathersurface. Such a contrast may be made more effective by employinggranules I2 of a different color from the granules 6 and is useful fordepicting ,bands of Ademarcation, as mortar bands, or shadowL effects.It is to be understood that this construction as well as the previouslydescribed edge treatments may be extended to all or a limited number ofedges.

Figs. 4 and 5 illustrate themultiplelayer formation of shingle units;Fig. 4 showing an arrangement in a fibre carton, and Fig. 5 of a bundlevof shingle units maintained between end members, for instance, of wood,by suitable surrounding straps. In this condition the adjacent faces areunder static pressure and the layer 8 forms a protective film,preventing bleeding of the saturant or skin layer asphalt-through to theweather surface of the `adjacent units. The same conditions will existwhere the material has been formed into rolls. Thus it lwill be obviousthat the protective lm of the invention is highly desirable where theweather exposed face of the material comprises light colored granules,whether they be of natural color or coated, or where such surface is oneof a cement surfacing of light color. In the latter case the waterinsoluble protective layer 8 will prevent discoloration of the cementduring the curing stage, particularly when such material is wet andplastic. However, the layer 8, even, protects the ornamental surfacingswhere they are of dark shades as any deposit of bitumen upon the exposedface is obviously undesirable. From Figs. 4 and 5 it will'also beapparent that as the units are removed, abrasion will readily occurbetween the weather face of one and the treated back of another.Likewise this action will be even more marked when the units are laidupon a surface, particularly in applying the material to a wall. Forthis normal character of handling, the layer 8 will provide thenecessary protection to prevent bituminous discoloration and marring ofthe exposed surface.

Where the layer 8 is one of the aforesaid phenolic resin character andis applied over the saturated base the open pores of the base absorb asubstantial amount of this composition and will receive additionalprotective properties. In combination with a cellulose fiber base thestructure may be made quite light in weight without loss of weatheringqualities and life to the structure.

It is desired that the4 invention be construed as including allequivalents and such modifications as may be readily made by one skilledin the art with the foregoing novel features in mind. Moreover theinvention may be applied with equal eiect to bitumen mastic products. Itis desired that the claims be construed as broadly as the prior art mayallow. The term roofing in the foregoing description and in the claimsis to be construed to include individual shingles, multi-shingle stripsand roll roofing and allsurface applications, for example, roofs andsidewalls of buildings.

I claim:

1. Roofing comprising a bitumen treated base, a rough ornamental weathersurfacing on one side of said base, and a hardened, substantiallywaterinsoluble metallic resinate coating upon the opposite side,'sealingin' the bitumen on said side and adapted to substantially preventdiscoloration thereby of the ornamental surfacing of similar roofingthrough bleeding in storage, said coating being also of suiiicientthickness and toughness to substantially prevent said discoloration bythe bitumen through normal scuiiing in storage and handling.

2. Roofing comprising a bitumen treated base, a rough ornamental Weathersurfacing on one side of said base, and a hardened, substantiallywater-insoluble calcium resinate coating upon the opposite side, sealingin the bitumen on said side and adapted to substantially preventdiscoloration thereby of the ornamental surfacing of similar roofingthrough bleeding in storage, said coating being also of suflicientthickness and toughness to substantially prevent said discoloration bythe bitumen through normal sculng in storage and handling.

3. Roofing comprising a bitumen treated base, a rough ornamental weathersurfacing on one side of said base, and a hardened, substantiallyWater-insoluble zinc resinate coating upon the opposite side, sealing inthe bitumen on said side and adapted to substantially preventdiscoloration thereby of the ornamental surfacing of similar roofingthrough bleeding in storage, said coating being also of sulcientthickness and toughness to substantially prevent said discoloration bythe bitumen through normal scumng in stor` age and handling.

4. Roong comprising a bitumen treated base, a rough ornamental weathersurfacing on one side of said base, and a hardened, substantiallywater-insoluble metallic resinate coating including a drying oil uponthe opposite side, said coating sealing in the bitumen on said side andadapted to substantially prevent discoloration thereby of the ornamentalsurfacing of similar roofing through bleeding in storage, said coatingbeing also of suicient thickness and toughness to substantially preventsaid discoloration by the bitument through normal scufling in storageand handling.

5. Roong comprising a bitumen treated base, a rough ornamental weathersurfacing comprising argillaceous cement on one side of said base, and ahardened, substantially water-insoluble metallic resinate coating uponthe opposite side, sealing in the bitumen on said side and adapted tosubstantially prevent discoloration thereby of the ornamental surfacingof similar roofing through bleeding in storage, said coating being alsoof sumcient thickness and toughness to substantially prevent saiddiscoloration by the bitumen through normal scuing in storage andhandling.

6. Roofing comprising a bitumen treated base, a rough ornamental weathersurfacing of light color effect on one side of said base, and ahardened, substantially water-insoluble metallic resinate coating uponthe opposite side, sealing in the bitumen on said side and adapted tosubstantially prevent discoloration thereby of the ornamental surfacingof similar roofing through bleeding in storage, said coating being alsoof sumcient thickness and toughness to substantially prevent saiddiscoloration by the bitumen through normal scuilng in storage andhandling.

SIDNEY A. OCHS.

